A device for pearl embroidery

Abstract

The application provides a special-shaped bead piece embroidery device and relates to the field of bead piece embroidery. The device comprises a base, a first driving assembly is installed at the bottom of the base, a supporting frame is installed at the top of the first driving assembly, a control member is installed on the outer wall of the right supporting frame, a second driving assembly is installed at the top of the supporting frame, a third driving assembly is installed at the front end of the second driving assembly, and a bead piece embroidery machine head is installed on the outer wall of the third driving assembly. The multi-dimensional carrier tape supply module is configured with an active feeding, a PID closed-loop tension control and an air floating support unit. The guide rail adopts a diamond-like carbon film low-friction coating, and the bottom of the cooperation rail is provided with a micropore array to form a uniform air cushion, so that the special-shaped bead piece is in a nearly frictionless suspension state, and the problems of snakelike swinging, gravity deviation, tension fluctuation, carrier tape stretching deformation and material stacking in high-speed conveying are effectively inhibited. The device is suitable for the continuous and stable conveying of asymmetric special-shaped bead pieces such as water-drop-shaped, star-shaped and polygonal bead pieces, and the conveying reliability and speed are improved.

Description

Technical Field

[0001] This invention relates to the field of sequin embroidery technology, specifically to an irregularly shaped sequin embroidery device. Background Technology

[0002] Sequin embroidery is an important technique for enhancing the artistic expression and added value of products. As modern fashion design becomes increasingly personalized and complex, the application of irregularly shaped sequins, such as teardrop, star, and polygonal shapes, is becoming more widespread. However, traditional sequin embroidery equipment faces significant challenges in handling these irregularly shaped sequins. Because the geometric center and center of gravity of irregularly shaped sequins often do not coincide and they possess significant asymmetry, problems such as instability, positional shifts, and serpentine swaying are easily generated during high-speed conveying, leading to serious deviations in the final stitching position. Existing feeding mechanisms typically employ simple physical constraints, resulting in high frictional resistance and static electricity accumulation in the carrier belt during sliding. Furthermore, their tension control systems lack sensitive feedback adjustment, and tension fluctuations during high-speed start-up and shutdown often cause carrier belt stretching deformation or material jamming.

[0003] Furthermore, existing pose detection methods are relatively limited, making it difficult to acquire real-time information on the rotational angle deviation and vertical warping of the sequins before shearing. This prevents the sewing needle from accurately aligning with the sewing hole during high-speed descent, significantly impacting sewing reliability. Regarding the actuator, the phase synchronization accuracy between traditional shearing systems and the sewing spindle is limited, easily leading to secondary displacement deviations during shearing. Simultaneously, traditional metal presser feet obstruct the sewing area, preventing the vision system from achieving closed-loop monitoring throughout the entire process. In terms of environmental adaptability, the mechanical vibrations generated by the equipment's high-frequency reciprocating motion, and the impact of temperature and humidity changes on the carrier material's flexibility, further reduce processing accuracy and shorten the lifespan of mechanical parts. Therefore, developing a device and system for embroidering irregularly shaped sequins that enables multi-dimensional pose accuracy perception, dynamic real-time compensation, low-friction air-float conveying, and environmental adaptive adjustment has become a critical technical challenge urgently needing to be addressed in the intelligent upgrading of textile machinery. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an irregular sequin embroidery device that solves the problems of misalignment between the center of gravity and geometric center, high-speed conveyor posture deviation, large fluctuations in carrier belt tension, poor phase synchronization of shearing and sewing, and obstruction of vision by the presser foot when processing irregular sequins in existing irregular sequin embroidery equipment.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: an irregular sequin embroidery device, comprising a base, a first driving component installed at the bottom of the base, a support frame installed at the top of the first driving component, a control component installed on the outer wall of the support frame on the right side, a second driving component installed at the top of the support frame, a third driving component installed at the front end of the second driving component, and a sequin embroidery machine head installed on the outer wall of the third driving component; The control components include a multi-dimensional carrier tape supply module, a visual pose detection module, a dynamic pose compensation module, a precision linkage shearing module, and a synchronous sewing execution module. The sequin embroidery machine head includes a feeding mechanism, a pressing mechanism, and a needle bar mechanism. The multi-dimensional carrier tape supply module is located inside the feeding mechanism and is used to convey the irregularly shaped sequin carrier tape with constant tension and form an air-bearing support on the guide rail. The visual pose detection module is installed above the detection station on the guide rail and is used to obtain the geometric center coordinates, rotational deviation angle, and warpage height of the irregularly shaped sequins before shearing. The dynamic pose compensation module is used to correct the pose of the irregularly shaped sequins by horizontal translation and rotation around the vertical axis based on the deviation data fed back by the visual pose detection module. The precision linkage shearing module is used to separate the irregularly shaped sequins from the carrier tape at a set phase angle on the needle bar spindle. The synchronous sewing execution module includes the pressing mechanism, the needle bar mechanism, and the rotary hook mechanism, and is used to sew the separated sequins onto the fabric.

[0006] Preferably, the multi-dimensional carrier belt supply module includes an active feeding mechanism, a tension buffer mechanism, a guide rail, an air-bearing support unit, and a residual belt recovery mechanism; the active feeding mechanism is driven by a first servo motor and equipped with an encoder; the tension buffer mechanism includes staggered fixed pulleys and movable pulleys, the movable pulleys are connected to a linear tension sensor, the linear tension sensor feeds back the instantaneous tension value to the controller, and the controller uses a proportional-integral-derivative control algorithm to dynamically adjust the speed of the first servo motor; the surface of the guide rail is coated with a diamond-like carbon film; the air-bearing support unit is integrated inside the guide rail and releases compressed air through a micro-hole array distributed at the bottom of the rail, forming a uniform air cushion between the bottom surface of the irregularly shaped beads and the surface of the rail; the residual belt recovery mechanism is driven by a second servo motor.

[0007] Preferably, the visual pose detection module includes a high frame rate industrial camera, a ring-shaped shadowless light source, and an image processing unit; the high frame rate industrial camera uses a global shutter photosensitive element; the ring-shaped shadowless light source uses an oblique illumination method; the image processing unit obtains the pixel area and centroid coordinates of the irregularly shaped beads by calculating the order moment of the image, and determines the principal axis direction and rotational deviation angle of the beads using the second-order central moment method; the visual pose detection module also includes a depth sensing unit, which uses the structured light triangulation principle to monitor the warping height of the irregularly shaped beads in the vertical direction.

[0008] Preferably, the dynamic pose compensation module includes a three-axis micro-motion platform, which has horizontal X-axis translational degree of freedom, Y-axis translational degree of freedom, and R-axis rotational degree of freedom about the central vertical axis; the three-axis micro-motion platform is driven by a stepper motor; the R-axis rotation mechanism adopts a hollow ring motor structure, and the carrier belt passes through the central aperture of the hollow ring motor; the dynamic pose compensation module adopts a predictive control algorithm, which combines historical compensation data with the current carrier belt motion vector to predict overshoot displacement and apply a reverse braking torque.

[0009] Preferably, the precision linkage shearing module includes a cutter assembly, a cam drive mechanism, and a waste cleaning mechanism; the cutter assembly is made of tungsten steel, and the blade shape is customized according to the connecting neck of the irregularly shaped beads; the cam drive mechanism and the main shaft of the needle bar mechanism are physically linked through a synchronous toothed belt, and the shearing action is limited to a predetermined range of the main shaft phase angle; the cutter assembly integrates a resistance heating wire, and performs the hot cutting process through closed-loop temperature control; the waste cleaning mechanism adopts a combination of pulse negative pressure adsorption and high-pressure air blowing; the precision linkage shearing module is also equipped with a tool wear monitoring device, which collects the vibration spectrum signal at the moment of shearing through a piezoelectric ceramic sensor, and the controller uses a preset characteristic frequency model to analyze the vibration spectrum to determine the state of the cutter blade.

[0010] Preferably, the pressing mechanism in the synchronous sewing execution module includes a special presser foot made of transparent ceramic material, with a countersunk hole on its bottom surface that matches the outer contour of the irregular sequins. The depth of the countersunk hole is 1.2 times the thickness of the sequins. The presser foot pressure of the pressing mechanism is controlled by an electronic proportional valve, and the control component dynamically adjusts the presser foot pressure based on feedback from the fabric thickness sensor. The needle bar stroke of the needle bar mechanism is finely adjusted by an eccentric shaft adjustment mechanism. The surface of the rotary hook mechanism is treated with ultra-hard titanium nitride and equipped with a micro-automatic lubrication module.

[0011] Preferably, the pressing mechanism in the synchronous sewing execution module includes a special presser foot made of transparent ceramic material, with a countersunk hole on its bottom surface that matches the outer contour of the irregular sequins. The depth of the countersunk hole is 1.2 times the thickness of the sequins. The presser foot pressure of the pressing mechanism is controlled by an electronic proportional valve, and the control component dynamically adjusts the presser foot pressure based on feedback from the fabric thickness sensor. The needle bar stroke of the needle bar mechanism is finely adjusted by an eccentric shaft adjustment mechanism. The surface of the rotary hook mechanism is treated with ultra-hard titanium nitride and equipped with a micro-automatic lubrication module.

[0012] Preferably, the multi-dimensional carrier tape supply module further includes a carrier tape specification automatic identification unit. The carrier tape specification automatic identification unit reads the barcode information on the edge of the carrier tape through a reflective photoelectric sensor and automatically retrieves the physical parameters of the corresponding specification sequins from a pre-stored database.

[0013] Preferably, the dynamic pose compensation module adopts an ultra-high frequency micro-motion platform driven by piezoelectric ceramics, and the displacement transmission mechanism adopts a flexible hinge structure; the visual pose detection module adopts a dual-camera collaborative mode, and the image processing unit adopts a deep learning convolutional neural network to identify the contour of the irregular bead; the precision linkage shearing module introduces a laser cutting module to melt the carrier tape connection part through a high-energy laser beam.

[0014] Preferably, the rotary hook mechanism of the synchronous sewing execution module adopts magnetic levitation support technology, suspending the rotary hook rotor through electromagnetic force; the needle bar mechanism is equipped with a linear motor for direct drive; the control unit adopts a distributed architecture based on edge computing, with each sub-module equipped with an independent microprocessor and supporting 5G wireless communication protocol. This invention provides an embroidery device for irregularly shaped sequins. It has the following beneficial effects: 1. This invention utilizes a multi-dimensional carrier belt supply module with active feeding, PID closed-loop tension control, and air-float support units. The guide track employs a diamond-like carbon film low-friction coating, which, combined with a micro-pore array at the bottom of the track, forms a uniform air cushion. This allows irregularly shaped beads to be in a near-frictionless suspension state, effectively suppressing problems such as serpentine swaying, center of gravity shift, tension fluctuation, carrier belt stretching deformation, and material stacking during high-speed conveying. It is suitable for the continuous and stable conveying of asymmetric irregularly shaped beads such as teardrop, star, and polygonal shapes, improving conveying reliability and speed.

[0015] 2. The visual pose detection module of this invention adopts a high frame rate global shutter camera, a ring shadowless light source and a depth sensing unit, which can acquire the geometric centroid coordinates, rotation deviation angle and vertical warping height of irregular sequins in real time before cutting. It achieves non-contact high-precision detection through image step moment algorithm and structured light triangulation, which solves the problem that traditional devices cannot identify sequin offset and warping in real time, resulting in inaccurate alignment of sewing holes, and provides accurate data support for subsequent pose correction.

[0016] 3. This invention employs a three-axis micro-motion platform (X / Y translation + R-axis rotation) through a dynamic pose compensation module, combined with predictive control algorithms and reverse braking logic. It can quickly complete horizontal translation and rotation correction based on visual detection data. The hollow ring motor structure of the R-axis shortens the detection and compensation distance, controlling the compensation stabilization time to the millisecond level. This effectively eliminates the pose deviation caused by the geometric characteristics and high-speed movement of irregularly shaped sequins, ensuring that the sequin sequin stitching hole and the needle bar trajectory are accurately aligned.

[0017] 4. This invention uses a precision linkage shearing module to physically link the synchronous toothed belt with the needle bar spindle, limiting the shearing action to a specific phase range of the spindle. Combined with a custom tungsten steel cutting tool and hot cutting process, it achieves precise separation of the beads and the carrier tape. The tool wear monitoring device monitors the cutting edge status in real time through vibration spectrum, and the waste cleaning mechanism efficiently removes debris, avoiding secondary displacement deviation and equipment jamming, and ensuring shearing accuracy and stability under high-speed processing.

[0018] 5. This invention uses a transparent ceramic special presser foot in the synchronous sewing execution module, which does not obstruct the visual detection light path and can realize closed-loop monitoring of the entire sewing process; the presser foot countersunk hole matches the sequin contour, the pressure is adaptive to the fabric thickness adjustment, the rotary hook mechanism is ultra-hardened and automatically lubricated, and the active shock-absorbing base counteracts mechanical vibration, solving the problems of traditional presser foot obstruction, unadjustable sewing pressure, and equipment vibration affecting accuracy, thus improving sewing quality and equipment life. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the structure of the first driving component of the present invention; Figure 3 This is a schematic diagram of the structure of the second driving component of the present invention; Figure 4 This is a schematic diagram of the control system and functional modules of the present invention; Figure 5 This is a schematic diagram of the operation process of the irregular sequin embroidery device of the present invention.

[0020] The components include: 1. base; 2. support frame; 3. sequin embroidery machine head; 4. first drive assembly; 5. control components; 6. second drive assembly; and 7. third drive assembly. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] like Figure 1-5 As shown, this embodiment of the invention provides an irregular sequin embroidery device, including a base 1, a first drive component 4 installed at the bottom of the base 1, a support frame 2 installed at the top of the first drive component 4, a control component 5 installed on the outer wall of the support frame 2 on the right side, a second drive component 6 installed at the top of the support frame 2, a third drive component 7 installed at the front end of the second drive component 6, and a sequin embroidery machine head 2 installed on the outer wall of the third drive component 7.

[0023] The control unit 5 includes a multi-dimensional carrier tape supply module, a visual pose detection module, a dynamic pose compensation module, a precision linkage shearing module, a synchronous sewing execution module, and a central coordination control module.

[0024] The feeding mechanism includes a multi-dimensional carrier tape supply module, controlled by controller 5. This module is responsible for conveying the rolled, irregularly shaped sequin carrier tape to the inspection and stitching area with constant tension. Specifically, the active feeding mechanism is driven by a first servo motor equipped with a high-line-count incremental encoder, generating over 10,000 pulses per revolution to acquire real-time rotor angular displacement data. Controller 5 executes pulse distribution logic based on preset sequin spacing parameters, calculating the pulse output of the first servo motor in each feed cycle, thus achieving micron-level control of the carrier tape output length.

[0025] On the conveying path, a tension buffer mechanism is installed between the active feeding mechanism and the guide rail. This mechanism utilizes a set of staggered fixed and movable pulleys to form a physical buffer space. The movable pulleys are mounted on a linear guide rail and mechanically connected to a linear tension sensor. The linear tension sensor continuously monitors the instantaneous tension value of the carrier belt during the conveying process and transmits this analog signal to the control unit 5 via an analog-to-digital converter circuit. When the carrier belt experiences tension fluctuations at high-speed start-up or stop, the control unit 5 dynamically adjusts the speed output of the first servo motor using a proportional-integral-derivative (PID) control algorithm. Its control logic satisfies the following formula: In the above formula, To control the output To account for the deviation between the preset tension range and the measured tension, The proportionality coefficient determines the strength of the response to the current deviation. These are integral coefficients used to eliminate long-term accumulated static bias. The differential coefficient is used to predict the trend of deviation changes and suppress system oscillations. Through this algorithm, the carrier belt tension is maintained within the preset range of 0.5 Newtons to 1.5 Newtons, eliminating the tensile deformation caused by excessive tension or the stacking phenomenon caused by insufficient tension.

[0026] The guide track, serving as the physical constraint path for the carrier tape, is coated with a diamond-like carbon film. This film possesses an extremely low coefficient of friction and extremely high surface hardness, reducing the resistance of the irregularly shaped beads during sliding. An air-bearing support unit is integrated within the guide track. This unit releases compressed air at a pressure of 0.3 MPa through a micro-pore array distributed at the bottom of the track, forming a uniform air cushion with a thickness of 20 to 50 micrometers between the bottom surface of the irregularly shaped beads and the track surface. This air cushion keeps the beads in a near-frictionless suspended state and, through the boundary layer effect formed by the airflow at the track edge, provides a lateral self-centering constraint force for the irregularly shaped beads, suppressing their serpentine swaying at high speeds. The residual tape recovery mechanism, located downstream of the sewing station and driven by a second servo motor, is responsible for neatly winding the sheared empty carrier tape onto the recovery reel. In addition, the multi-dimensional carrier tape supply module also includes an automatic carrier tape specification identification unit. This unit reads the barcode information on the edge of the carrier tape through a reflective photoelectric sensor and automatically retrieves the physical parameters of the sequins of that specification from a pre-stored database, including the outer contour size unit, the center of gravity offset unit, and the recommended stitching tension value, so as to realize the rapid line changeover and zero-debugging start-up of the production line.

[0027] The sequin embroidery machine head 8 integrates a visual pose detection module, installed above a key detection station on the guide rail, to acquire the real-time spatial state of the sequins before the cutting action. The module includes a high-frame-rate industrial camera, a ring-shaped shadowless light source, and an image processing unit. The high-frame-rate industrial camera uses a global shutter sensor with a capture frequency set to 200 frames per second, ensuring no motion blur in the captured images during high-speed belt movement. The ring-shaped shadowless light source uses a 45-degree oblique illumination method, eliminating shadows caused by the thickness of irregularly shaped sequin edges through diffuse reflection, acquiring high-contrast contour images. After receiving the image data, the image processing unit first performs Gaussian filtering for noise reduction, then uses an edge detection operator with an adaptive threshold to extract the closed contour curve of the sequins. The image processing unit obtains the physical characteristics of the sequins by calculating the image's moment of inertia. The formula for calculating the step moment is: in Representing an image Step moment, This represents the grayscale value of a pixel in the coordinate system. Representing an image The moment of order is used to describe the spatial distribution of pixel gray values ​​in an image. Represents the x and y coordinates of pixels in an image. Indicates coordinates The grayscale value (0~255) at that location. The image processing unit calculates the 0th order moment. Obtain the pixel area of ​​the sequins using a first-order moment. and Calculate the coordinates of the center of gravity of the sequins:

[0028] in: : Pixel coordinates of the geometric centroid of the sequins The first moment reflects the distribution of grayscale values ​​in the x and y directions. The total pixel area of ​​the sequins. Using the second-order central moment method, the module further determines the principal axis direction of the sequins and compares it with the reference axis under the standard pose to obtain the rotational deviation angle. in, Represents the central moment, This is the rotational deviation angle of the current spindle direction relative to the standard pose. The second-order central moments are represented by the image's product of inertia, the horizontal moment of inertia, and the vertical moment of inertia, respectively. The visual pose detection module also includes a depth sensing unit. This unit utilizes the structured light triangulation principle to monitor the warping height of the irregularly shaped sequins in the vertical direction in real time by projecting grid stripes and analyzing their distortion. If the detected warping value of the sequins exceeds 0.2 mm, the unit automatically triggers an alarm and instructs the dynamic pose compensation module to adjust the downward pressure to ensure that the sewing needle penetrates the pre-set sewing hole of the sequins.

[0029] The sequin embroidery machine head 8 also integrates a dynamic pose compensation module, which receives feedback data from the visual pose detection module and performs physical corrections. This module includes a three-axis micro-motion platform with horizontal X-axis translational freedom, Y-axis translational freedom, and R-axis rotational freedom around the central vertical axis. The three-axis micro-motion platform is driven by a high-resolution stepper motor, with a displacement accuracy of 1 micrometer and a rotational accuracy of 0.01 degrees corresponding to a single pulse. The X-axis and Y-axis guide rails use zero-backlash pre-tensioned linear rolling guide rails to ensure the repeatability and positioning accuracy of the compensation action. The R-axis rotation mechanism adopts a hollow ring motor structure, with the carrier belt passing directly through the central aperture of the motor. This coaxial design reduces the physical distance between the detection point and the compensation point to within 30 millimeters, improving the module's dynamic response frequency. When performing correction actions, the dynamic pose compensation module uses a predictive control algorithm, combining historical compensation data with the current carrier belt's motion vector, to predict the overshoot displacement of the irregular sequins when they reach the shearing point, and applies a reverse braking torque in advance in the motor drive circuit. Through this proactive compensation mechanism, the module can control the stabilization time of the compensation action to within 5 milliseconds.

[0030] The sequin embroidery machine head 8 also integrates a precision linkage shearing module, responsible for separating irregularly shaped sequins from the carrier tape at preset phase points. This module includes a cutter assembly, a cam drive mechanism, and a waste cleaning mechanism. The cutter assembly is made of high-hardness tungsten steel, and its blade shape is customized geometrically based on the connecting neck of the irregularly shaped sequins. The cutter assembly supports a quick-change structure, with manual levers used for positioning and locking the cutter. The cam drive mechanism and the needle bar spindle of the synchronous sewing execution module are physically linked via a synchronous toothed belt, ensuring absolute phase synchronization between the shearing action and the sewing needle position. The shearing action is limited to a spindle phase angle of 270 to 300 degrees, at which point the needle bar mechanism is at its top dead center and the clamping mechanism is in a raised state. The precision linkage shearing module is also equipped with a cutter wear monitoring device, which collects the vibration spectrum signal at the moment of shearing through a piezoelectric ceramic sensor installed at the bottom of the cutter holder. And perform a Fourier transform to obtain the power spectral density.

[0031] Control component 5 uses a preset characteristic frequency model to... An analysis was conducted. Among them: The power spectral density of a vibration signal represents the energy distribution of its different frequency components. : Instantaneous shear vibration signal (time domain) acquired by piezoelectric ceramic sensor. Frequency variable, unit: , When the amplitude of a specific frequency component exceeds the normal reference value by 20%, the cutting edge is determined to be chipped, and a replacement warning is triggered on the operation interface. The cutting assembly also integrates a resistance heating wire, which maintains the blade temperature at 60 degrees Celsius through closed-loop temperature control, performing a hot cutting process to instantly melt and seal the carrier tape cut edge. The waste cleaning mechanism uses a combination of pulsed negative pressure adsorption and high-pressure air blowing to ensure that the generated carrier tape debris enters the collection container.

[0032] The synchronous sewing execution module consists of a pressing mechanism, a needle bar mechanism, and a rotary hook mechanism. The special presser foot in the pressing mechanism is made of transparent ceramic material, which has excellent optical transmittance, allowing the optical axis of the visual pose detection module to penetrate the presser foot and observe the real-time status of the sewing point, achieving closed-loop monitoring of the entire sewing process. The bottom surface of the special presser foot is machined with countersunk holes matching the outer contour of the irregular sequins, with a depth set to 1.2 times the thickness of the sequins, used to physically limit the sequins at the moment of sewing. The presser foot pressure is controlled by an electronic proportional valve, and the control component 5 dynamically adjusts it between 10 Newtons and 50 Newtons based on feedback from the fabric thickness sensor. Driven by the central coordination control module, the needle bar mechanism works in conjunction with the rotary hook mechanism to complete the lockstitch sewing. The needle bar stroke is finely adjusted within the range of 15 mm to 25 mm via an eccentric shaft adjustment mechanism. The rotary hook mechanism has a surface treated with ultra-hard titanium nitride and works in conjunction with a micro-automatic lubrication module to complete continuous operation. The device is installed on a base with active vibration damping function. The base has four electromagnetic actuators that sense vibrations through accelerometers and generate counteracting forces with opposite phases to reduce the vibration amplitude of the machine head.

[0033] The operation process of the irregular sequin embroidery device of the present invention is as follows: S1. In the start-up phase, the multi-dimensional carrier belt supply performs constant tension feeding. The first servo motor drives the carrier belt forward according to the pulse sequence allocated by the control unit 5. The tension buffer mechanism obtains feedback through a linear tension sensor and uses a PID algorithm to stabilize the carrier belt tension at approximately 1.0 Newtons. Supported by the high-pressure air cushion generated by the air-bearing support unit, the carrier belt passes through the guide rail in a frictionless state.

[0034] S2. During the inspection phase, when the irregularly shaped sequins arrive at the visual pose detection station, a high frame rate industrial camera, in conjunction with a ring-shaped shadowless light source, captures the contour image of the sequins. The image processing unit runs a moment calculation program to obtain the geometric centroid coordinates of the sequins. and the rotational deviation angle relative to the standard axis The depth sensing module simultaneously detects whether there is warping exceeding 0.2 mm on the surface of the beads.

[0035] S3, Compensation Phase: Controller 5 converts the deviation vector fed back from the vision module into motion commands for the three-axis micro-motion platform. The dynamic pose compensation module drives the X-axis, Y-axis, and R-axis stepper motors, completing translation and rotation corrections within 5 milliseconds. The hollow ring motor structure of the R-axis ensures that the carrier tape does not twist during rotation, aligning the center line of the sewing hole of the sequins with the motion trajectory of the needle bar mechanism.

[0036] S4. During the shearing stage, as the needle bar spindle rotates to a 270-degree phase angle, the cam drive mechanism triggers the shearing action. The tungsten carbide cutter, aided by a resistance heating wire, performs thermal separation of the connecting parts. Simultaneously, a pulsed negative pressure adsorption mechanism is activated, sucking the generated carrier tape debris into a collection container. The cutter wear monitoring device confirms the cutter's normal condition by analyzing the power spectral density of the vibration spectrum.

[0037] S5, during the sewing stage, the cut sequins enter under the special presser foot. An electronic proportional valve adjusts the presser foot pressure according to the fabric thickness, and the countersunk hole at the bottom of the transparent ceramic presser foot physically limits the sequins. The needle bar mechanism 32 drives the sewing needle to penetrate the sequin holes, cooperating with the rotary hook mechanism to complete the sewing. The electromagnetic actuator of the active shock-absorbing base generates a counterforce based on the vibration frequency, counteracting the impact of the needle bar's reciprocating motion.

[0038] In another preferred embodiment, the dynamic pose compensation module employs an ultra-high frequency micro-motion platform driven by piezoelectric ceramics, and the displacement transmission mechanism uses a flexible hinge structure. The flexible hinge achieves motion transmission through the elastic deformation of the metal material, eliminating mechanical friction and backlash errors, thus achieving nanometer-level compensation accuracy. The visual pose detection module is upgraded to a dual-camera collaborative mode, and the image processing unit uses a deep learning convolutional neural network to identify the contours of irregularly shaped sequins. The precision linkage shearing module introduces a laser cutting module, which instantly melts the carrier tape connection part with a high-energy laser beam, achieving non-contact processing. The laser power is dynamically adjusted according to the carrier tape conveying speed to maintain cut consistency.

[0039] The rotary hook mechanism of the synchronous sewing execution module employs magnetic levitation support technology, using electromagnetic force to suspend the rotary hook rotor within the stator cavity, eliminating the need for physical contact and lubrication. The needle bar mechanism is equipped with a linear motor for direct drive, allowing the needle bar's motion curve to be digitally customized according to the fabric material. The central coordination control module has been upgraded to a distributed architecture based on edge computing, with each submodule equipped with an independent microprocessor. Wavelet transform is used to perform multi-scale decomposition of the shear vibration signal; the calculation formula is as follows:

[0040] This formula is used to extract characteristic components related to cutting force, enabling preventative maintenance. Wavelet transform coefficients represent the signal's scaling. Local features at position b Time-domain vibration signal The complex conjugate of wavelet basis functions (mother wavelet). The scaling parameter controls the stretching or compression of the wavelet. Translation parameters control the wavelet's position on the time axis. The control module supports 5G wireless communication protocols, enabling seamless collaboration between devices.

[0041] In practical applications, when the device processes teardrop-shaped irregular beads, the center of gravity of the beads is significantly offset towards the curved end. Traditional geometric center positioning can cause the beads to deflect during high-speed transport. This device extracts the center of gravity coordinates in real time through a visual pose detection module, and the R-axis mechanism of the dynamic pose compensation module adjusts the position based on the deviation angle. Reverse rotation compensation is performed. When the ambient humidity is below 30%, causing increased brittleness of the carrier belt, the environmental adaptive adjustment unit instructs the control unit 5 to lower the tension setting by 15% and increase the current of the cutting blade heating wire to ensure a good hot-cutting effect. The transparent ceramic material of the special presser foot allows the operator to observe real-time images of the seam points through an auxiliary camera. If a skipped thread abnormality occurs, the module immediately performs an emergency brake.

[0042] Furthermore, the micropore array design of the air-bearing support unit fully utilizes the throttling effect of fluid mechanics. Compressed air passes through 0.1 mm micropores, forming a highly rigid air film beneath the beads. This air film not only provides support but also removes frictional heat through continuous airflow, protecting the coating layer on the bead surface. The pressure gradient formed by the air cushion at the track edge generates an inward restraining force, which, combined with the active correction of the dynamic posture compensation module, constitutes a dual precision assurance mechanism. The electromagnetic actuator of the active damping base uses high-performance rare-earth permanent magnet materials with a response frequency of 1000 Hz. By real-time monitoring of the frame vibration spectrum, it identifies and avoids resonance points at different speeds, providing a stable physical environment for visual inspection.

[0043] The waste cleaning mechanism of the precision linkage shearing module, in its advanced configuration, incorporates an electrostatic eliminator. By injecting positive and negative ions into the high-pressure airflow, it neutralizes the electrostatic charge on the carrier belt debris, eliminating the risk of fine debris adhering to the rotary hook mechanism due to electrostatic attraction. The cleaning effect is monitored in a closed-loop manner by photoelectric sensors; if debris accumulation is detected, the module automatically increases the intensity of the pulsed airflow. The special presser foot also integrates an ultrasonic-assisted vibration module. When sewing ultra-thick fabrics, the presser foot generates high-frequency micro-amplitude vibrations, reducing needle penetration resistance and resulting in smooth stitches.

[0044] The dual-core architecture of the central coordination and control module achieves task decoupling. The field-programmable gate array (FPGA) processes multi-channel encoder feedback and motor drive signals in parallel through hardware logic, ensuring that the synchronization error of multi-axis linkage is less than one pulse cycle. The high-performance embedded processor is responsible for running complex predictive compensation algorithms and cloud interconnection logic. Through the industrial Ethernet interface, the equipment's operating current, motor temperature, and fault logs are uploaded to the cloud management platform in real time, and big data analysis technology is used to predict the fatigue life of the mechanical structure. This hardware and software co-design enables the device to maintain a stitching accuracy within 0.05 mm at an extreme speed of 2000 stitches per minute.

[0045] In summary, this invention constructs a closed-loop intelligent manufacturing process through the stable delivery of the multi-dimensional carrier tape supply module, the precise perception of the visual pose detection module, the real-time correction of the dynamic pose compensation module, the phase shearing of the precision linkage shearing module, and the stable stitching of the synchronous stitching execution module. Under the unified scheduling of the central coordination and control module, each module achieves deep integration of mechanics, electronics, vision, and algorithms, solving the positioning and synchronization problems of irregularly shaped beads in the high-speed stitching process.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An irregular sequin embroidery device, comprising a base (1), characterized in that: The base (1) has a first drive assembly (4) installed at the bottom, a support frame (2) installed at the top of the first drive assembly (4), a control component (5) installed on the outer wall of the support frame (2) on the right side, a second drive assembly (6) installed at the top of the support frame (2), a third drive assembly (7) installed at the front end of the second drive assembly (6), and a sequin embroidery machine head (2) installed on the outer wall of the third drive assembly (7). The control unit (5) includes a multi-dimensional carrier tape supply module, a visual pose detection module, a dynamic pose compensation module, a precision linkage shearing module, and a synchronous sewing execution module; the sequin embroidery machine head includes a feeding mechanism, a pressing mechanism, and a needle bar mechanism; the multi-dimensional carrier tape supply module is located inside the feeding mechanism and is used to convey the irregular sequin carrier tape with constant tension and form an air-floating support on the guide rail; the visual pose detection module is installed above the detection station on the guide rail and is used to obtain the geometric center coordinates, rotation deviation angle, and warping height of the irregular sequin before shearing; the dynamic pose compensation module is used to perform horizontal translation and rotation around the vertical axis pose correction on the irregular sequin according to the deviation data fed back by the visual pose detection module; the precision linkage shearing module is used to separate the irregular sequin from the carrier tape at a set phase angle on the needle bar spindle; the synchronous sewing execution module includes a pressing mechanism, a needle bar mechanism, and a rotary shuttle mechanism, and is used to sew the separated sequin onto the fabric.

2. The irregular sequin embroidery device according to claim 1, characterized in that: The multidimensional carrier belt supply module includes an active feeding mechanism, a tension buffer mechanism, a guide rail, an air-bearing support unit, and a residual belt recovery mechanism; the active feeding mechanism is driven by a first servo motor and equipped with an encoder; the tension buffer mechanism includes staggered fixed pulleys and movable pulleys, the movable pulleys are connected to a linear tension sensor, the linear tension sensor feeds back the instantaneous tension value to the control unit (5), and the control unit (5) uses a proportional-integral-derivative control algorithm to dynamically adjust the speed of the first servo motor; the surface of the guide rail is coated with a diamond-like carbon film; the air-bearing support unit is integrated inside the guide rail and releases compressed air through a micro-hole array distributed at the bottom of the rail to form a uniform air cushion between the bottom surface of the irregular bead and the surface of the rail; the residual belt recovery mechanism is driven by a second servo motor.

3. The irregular sequin embroidery device according to claim 1, characterized in that: The visual pose detection module includes a high frame rate industrial camera, a ring-shaped shadowless light source, and an image processing unit. The high frame rate industrial camera uses a global shutter sensor. The ring-shaped shadowless light source uses oblique illumination. The image processing unit obtains the pixel area and centroid coordinates of the irregularly shaped beads by calculating the order moment of the image, and determines the principal axis direction and rotational deviation angle of the beads using the second-order central moment method. The visual pose detection module also includes a depth sensing unit, which uses the structured light triangulation principle to monitor the warping height of the irregularly shaped beads in the vertical direction.

4. The irregular sequin embroidery device according to claim 1, characterized in that: The dynamic pose compensation module includes a three-axis micro-motion platform, which has horizontal X-axis translational degree of freedom, Y-axis translational degree of freedom, and R-axis rotational degree of freedom about the central vertical axis. The three-axis micro-motion platform is driven by a stepper motor. The R-axis rotation mechanism adopts a hollow ring motor structure, and the carrier belt passes through the central aperture of the hollow ring motor. The dynamic pose compensation module adopts a predictive control algorithm, which combines historical compensation data with the current motion vector of the carrier belt to predict overshoot displacement and apply a reverse braking torque.

5. The irregular sequin embroidery device according to claim 1, characterized in that: The precision linkage shearing module includes a cutter assembly, a cam drive mechanism, and a waste cleaning mechanism. The cutter assembly is made of tungsten steel, and the blade shape is customized according to the connecting neck of the irregular bead. The cam drive mechanism and the main shaft of the needle bar mechanism are physically linked by a synchronous toothed belt, and the shearing action is limited to a predetermined range of the main shaft phase angle. The cutter assembly integrates a resistance heating wire and performs the hot cutting process through closed-loop temperature control. The waste cleaning mechanism adopts a combination of pulse negative pressure adsorption and high-pressure blowing. The precision linkage shearing module is also equipped with a tool wear monitoring device. This device collects the vibration spectrum signal at the moment of shearing through a piezoelectric ceramic sensor. The control component (5) analyzes the vibration spectrum using a preset characteristic frequency model to determine the state of the cutter blade.

6. The irregular sequin embroidery device according to claim 1, characterized in that: The pressing mechanism in the synchronous sewing execution module includes a special presser foot, which is made of transparent ceramic material and has a countersunk hole on its bottom surface that matches the outer contour of the irregular sequins. The depth of the countersunk hole is 1.2 times the thickness of the sequins. The presser foot pressure of the pressing mechanism is controlled by an electronic proportional valve. The control component (5) dynamically adjusts the presser foot pressure according to the feedback from the fabric thickness sensor. The needle bar stroke of the needle bar mechanism is finely adjusted by an eccentric shaft adjustment mechanism. The surface of the rotary hook mechanism is treated with ultra-hard titanium nitride and equipped with a micro-automatic lubrication module.

7. The irregular sequin embroidery device according to claim 1, characterized in that: The device also includes an active damping base, on which multiple electromagnetic actuators are distributed. These electromagnetic actuators sense vibrations through accelerometers and generate counteracting forces with opposite phases.

8. The irregular sequin embroidery device according to claim 1, characterized in that: The multidimensional carrier tape supply module also includes a carrier tape specification automatic identification unit. The carrier tape specification automatic identification unit reads the barcode information on the edge of the carrier tape through a reflective photoelectric sensor and automatically retrieves the physical parameters of the corresponding specification sequins from a pre-stored database.

9. The irregular sequin embroidery device according to claim 1, characterized in that: The dynamic pose compensation module adopts an ultra-high frequency micro-motion platform driven by piezoelectric ceramics, and the displacement transmission mechanism adopts a flexible hinge structure; the visual pose detection module adopts a dual-camera collaborative mode, and the image processing unit adopts a deep learning convolutional neural network to identify the contours of irregularly shaped beads; the precision linkage shearing module introduces a laser cutting module, which melts the carrier tape connection part through a high-energy laser beam.

10. The irregular sequin embroidery device according to claim 1, characterized in that: The rotary shuttle mechanism of the synchronous sewing execution module adopts magnetic levitation support technology, which levitates the rotary shuttle rotor through electromagnetic force; the needle bar mechanism is equipped with a linear motor for direct drive; the control unit (5) adopts a distributed architecture based on edge computing, with each sub-module equipped with an independent microprocessor and supporting 5G wireless communication protocol.

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